Suture anchor system with threaded plug

ABSTRACT

A suture anchor system including an anchor, a plug and an inserter. The anchor inserter includes a tubular outer shaft having a cannulation dimensioned to receive an inner shaft. The distal end of the outer shaft cannulation is threaded for engagement with the plug. The anchor includes a longitudinal cannulation formed within the anchor body, including a smooth-sided portion and a threaded portion. An eyelet, dimensioned to receive a suture therein, extends transverse to the longitudinal axis of the anchor and intersects the distal portion of the cannulation. The plug is a generally elongated, tubular threaded rod comprising a cannulation adapted to receive a distal end of the inner inserter shaft.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. application Ser. No. 15/738,329 filed Dec. 20, 2017, which is a U.S. 371 Application of International Application No. PCT/US2015/038460, filed Jun. 30, 2015, entitled “SUTURE ANCHOR SYSTEM WITH THREADED PLUG.”

BACKGROUND

Arthroscopy surgery is a minimally-invasive surgery that involves the repair of tissue inside or around a joint. In shoulder arthroscopy, for example, common injuries include a torn or damaged cartilage ring or ligaments (causing shoulder instability), a torn rotator cuff, or a torn or damaged biceps tendon. Each of these injuries necessitates the reattachment of soft tissue (that is, the ligaments or tendons) to bone.

Suture anchors and suture anchor systems are useful fixation devices for fixing tendons and ligaments to bone. A typical suture anchor is inserted into the bone by pounding the suture anchor into the bone or by way of a bone hole using an anchor inserter. The suture anchor can be configured as a screw mechanism or an interference fit device and may be made of metal, plastic or bioabsorbable material (which dissolves in the body over time). The suture anchor can include an eyelet that allows one or more sutures to pass therethrough and link the suture anchor and the suture.

During the anchor insertion process, it is difficult for a surgeon to achieve linear stability of the suture anchor while it is coupled to a mating, disposable inserter. Currently, an additional suture which is wrapped through the anchor and cleated to the inserter handle is often used to achieve linear stability. This method creates an additional strand of suture which can gets in a surgeon's way during a procedure. Other suture anchors are couple to inserters with press fits or other suture constructs which also may cause obstruction.

SUMMARY

Accordingly, there is a need for a suture anchor system and method to fix an anchor to an inserter before insertion into bone, and to release the anchor from the inserter after completion, without adding additional steps for the surgeon. Additional advantages of such a system would be superior fixation force, and a streamlined design that would be more cost-effective to manufacture than current suture anchor systems.

Described herein is a suture anchor system including an anchor inserter, a corresponding suture anchor, and a plug adapted for transfer from the anchor inserter to the anchor.

In one example, a suture anchor system of this disclosure can include: 1) an inserter having an elongated, cannulated outer shaft extending between a proximal end and a distal end, a distal end of the outer shaft being threaded; 2) an anchor having an elongated anchor body extending longitudinally between a proximal end and a distal end, a closed eyelet, extending transversely through a longitudinal axis of the anchor, and dimensioned to receive one or more sutures, and a cannulation formed within the anchor body and intersecting the eyelet, the cannulation including a proximal cannulation portion extending distally from the proximal end of the anchor body to a first longitudinal position proximal to the eyelet, and a threaded distal cannulation portion extending distally from the first longitudinal position to a second longitudinal position distal to the eyelet; and 3) a threaded, tubular plug having a longitudinal cannula extending between a proximal end and a distal end. The inner shaft of the inserter may be engageable with the cannula of the plug to move the plug distally with respect to the anchor from a first axial position to a second axial position. In the first axial position, the plug can engage both the anchor body and the outer shaft of the inserter and a distal terminus of the plug may be proximal to the eyelet. In the second axial position, the plug can engage the anchor body, but not the outer shaft of the inserter, and the distal terminus of the plug can abut a distal terminus of the anchor body cannulation. The inserter can be made of any type of metal. A diameter of the distal end of the inserter can be smaller than a diameter of the rest of the inserter. A size of the distal end of the inserter may be selected to couple with the proximal cannulation portion of the anchor. The anchor can be made of one of a plastic, a bioabsorbable material and/or a metal. The distal end of the anchor body may be closed. The proximal cannulation portion of the anchor can be non-threaded. Moving the plug distally with respect to the anchor may includes rotating the inner shaft of the inserter. The plug can be made of any one of a plastic, a bioabsorbable material and/or a metal. A plug length may be between about 5 mm and about 8.5 mm and a plug diameter may be between about 1.9 mm and about 2.1 mm.

In another example, a method of securing a suture of this disclosure can include: 1) routing a suture through an eyelet dimensioned to receive one or more sutures extending transversely through a longitudinal axis of an anchor, the anchor further having an elongated anchor body extending longitudinally between a proximal end and a distal end and a cannulation formed within the anchor body and intersecting the eyelet, the cannulation including a proximal cannulation portion extending distally from the proximal end of the anchor body to a first longitudinal position proximal to the eyelet, and a threaded distal cannulation portion extending distally from the first longitudinal position to a second longitudinal position distal to the eyelet; 2) engaging a distal end of a threaded, tubular plug with the distal cannulation portion of the anchor, the plug further having a longitudinal cannula extending between a proximal end and a distal end; 3) engaging a proximal end of the plug with a threaded distal end of a cannulation of an outer shaft of an inserter, the inserter further having an elongated inner shaft extending between a proximal end and a distal end, the inner shaft being dimensioned for receipt within and axially moveable independent of the outer shaft; 4) inserting the threaded distal end of the cannulation of the outer shaft of the inserter within the proximal cannulation portion of the anchor; and 5) engaging the inner shaft of the inserter with the cannula of the plug to move the plug distally with respect to the anchor from a first axial position, where the plug engages both the anchor body and the outer shaft of the inserter and a distal terminus of the plug is proximal to the eyelet, to a second axial position, where the plug engages the anchor body but not the outer shaft of the inserter and the distal terminus of the plug abuts a distal terminus of the anchor body cannulation, whereby the suture is secured between the distal terminus of the plug and the distal terminus of the anchor body cannulation. The method may further include removing the inserter from the anchor.

The advantages of this design is a streamlined device assembly in a neat, contained and reliable fashion, and may present cost benefits during manufacture. Furthermore, this form of fixation is far superior than other systems in terms of fixation force. Finally, the total number of steps in a surgical procedure is reduced, since there is no need to remove an extra suture.

For a better understanding of the present disclosure, together with other and further needs thereof, reference is made to the accompanying drawings and the following detailed description.

BRIEF DESCRIPTION OF THE DRAWINGS

The foregoing and other objects, features and advantages of the invention will be apparent from the following more particular description of the examples, as illustrated in the accompanying drawings, in which:

FIG. 1A is an exploded view of an example of the suture anchor system of this disclosure;

FIG. 1B is an isometric view of an example of the inserter of FIG. 1A;

FIGS. 2A and 2B are illustrations of further examples of the suture anchor system of this disclosure;

FIGS. 2C and 2D are illustrations of an example of the method of using the suture anchor system of this disclosure; and

FIG. 3 is an alternative example of the suture anchor system of this disclosure.

DETAILED DESCRIPTION

In the description that follows, like components have been given the same reference numerals, regardless of whether they are shown in different examples. To illustrate an example(s) of the present invention in a clear and concise manner, the drawings may not necessarily be to scale and certain features may be shown in somewhat schematic form.

Features that are described and/or illustrated with respect to one example may be used in the same way or in a similar way in one or more other examples and/or in combination with or instead of the features of the other examples.

As used in the specification and in the claims, the singular form of “a”, “an”, and “the” include plural referents unless the context clearly dictates otherwise.

As used in the specification and in the claims, for the purposes of describing and defining the invention, the terms “about” and “substantially” are used represent the inherent degree of uncertainty that may be attributed to any quantitative comparison, value, measurement, or other representation. The terms “about” and “substantially” are also used herein to represent the degree by which a quantitative representation may vary from a stated reference without resulting in a change in the basic function of the subject matter at issue.

Referring now to FIG. 1A, an exploded, cross-sectional view of an example of the suture anchor system 100 of this disclosure is shown. The suture anchor system 100 generally includes a suture anchor 102, a threaded plug 104, and an inserter 106. The suture anchor 102 can have a solid, hard barb design, as shown in FIG. 1A, although other anchor designs are possible. The suture anchor 102 can also be a pound in device or a screw in device. The suture anchor 102 may be completely, or portions thereof, made from a formulation of poly(lactic-co-glycolic) acid (PLGA), B-Tricalcium phosphate (B-TCP) and calcium sulfate, poly-L-lactic acid-hydroxyapatite (PLLA-HA), poly-D-lactide (PDLA), polyether ether ketone (PEEK) or variants thereof. Biocomposite embodiments of the suture anchor made from a combination of PLGA, B-TCP, and calcium sulfate are absorbable by the body, which is beneficial to natural healing. An example formulation of PLGA, B-TCP, and calcium sulfate is described in U.S. Pat. No. 8,545,866, the entirety of which is herein incorporated by reference. Other commonly used material for suture anchors are also contemplated by this disclosure.

The threaded plug 104 of the suture anchor system 100 is substantially tubular and includes a cannula 126 extending from a proximal to a distal end. A plug length may be between about 5 mm and about 8.5 mm. A plug diameter may be between about 1.9 mm and about 2.1 mm. The plug 104 may be fully threaded about its surface or, as shown in FIG. 1A, may have a distal portion that is unthreaded. The plug 104 may be made of a plastic, metal, or bioabsorable material. The distal end of the plug 104 may be open and in communication with the cannula 126 or may be closed-ended. The cannula 126 may extend distally through the entire length of the plug 104 or to any functional distance proximal thereto. The cannula 126 is dimensioned to receive an inner shaft 112 of the inserter 106, as further described below.

The inserter 106 of the suture anchor system 100 includes an elongated, cannulated outer shaft 108 extending between a proximal end and a distal end of the inserter 106. An inner surface of a distal end 124 of the outer shaft 108 further has threads 110 to engage the threads of the plug 104. A diameter of the distal end 124 is smaller than a diameter of any portion of the rest of the inserter 106, so that when the distal end of the outer shaft 108 is inserted into the anchor 102 (as described below), the anchor is fully seated against the rest of the inserter 106. The inserter 106 also has an elongated inner shaft 112 extending between a proximal end and a distal end of the inserter 106. The inner shaft 112 is dimensioned for receipt within the outer shaft 108 and is axially moveable independent of the outer shaft 108. FIG. 1B is an isometric view of the inserter 106, further illustrating the threads 110 on the inner surface of the distal end 124. The inserter 106, including the outer shaft 108 and inner shaft 112, can be made from any type of metal or other suitable material.

Referring now to FIGS. 2A and 2B, the suture anchor 102 includes an elongated anchor body 114 extending longitudinally between a proximal end and a closed distal end. The suture anchor 102 also has a closed eyelet 116, extending transversely through a longitudinal axis of the anchor 102, and dimensioned to receive one or more sutures (not shown). The anchor 102 further includes a suture anchor cannulation 118 formed within the anchor body 114 and intersecting the eyelet 116. The suture anchor cannulation 118 has a smooth-sided (e.g. non-threaded) proximal cannulation portion 120 extending distally from a proximal end (P) of the anchor body 114 to a first longitudinal position (L₁) proximal to the eyelet 116, and a threaded distal cannulation portion 122 extending distally from the first longitudinal position (L₁) to a second longitudinal position (L₂) distal to the eyelet 116. FIG. 2A shows the threaded plug 104 joining the anchor 102 to the inserter 106, as further described below. FIG. 2B shows the threaded plug 104 no longer joining the anchor 102 to the inserter 106, as further described below.

In use, as shown in FIG. 2C, the anchor 102 is mounted to the inserter 106 by means of the threaded plug 104, which is engaged with both the anchor 102 and the inserter 106, as described herein. A suture 128 may be first routed through the eyelet 116. The threaded distal end 124 of the outer shaft 108 of the inserter 106 is inserted within the proximal cannulation portion 120 of the anchor 102. The distal end of the threaded plug 104 is engaged with the distal cannulation portion 122 of the anchor 102 while the proximal end of the threaded plug 104 is engaged with the threads 110 of the distal end 124 of the outer shaft 108. This position defines a first axial position wherein the threaded plug 104 engages both the anchor body 114 and the outer shaft 108 of the inserter 106 and the distal terminus of the threaded plug 104 is proximal to the eyelet 116. So positioned, the threaded plug 104 advantageously secures the anchor 102 to the inserter 106 and also provides a bridge for transmission of force between the anchor 102 and inserter 106 during the anchor insertion process. In addition, this arrangement means that there is less opportunity for a surgeon to accidentally knock the anchor 102 off of the inserter 106. The surgeon will therefore be able to advance the suture anchor system 100 in and out of a surgical cannula more reliably.

As shown in FIG. 2D, after insertion of the anchor 102 into a bone hole of a patient (not shown), the suture 128 is secured to the anchor 102, as described herein. The inner shaft 112 of the inserter 106 is distally advanced through the cannula 126 of the threaded plug 104 by rotation of the inner shaft 112 by a means of a part of a handle attached to the inserter 106 (not shown). Additional distal advancement of the inner shaft 112 to the distal end of the cannula 126 urges the threaded plug 104 distally into the distal cannulation portion 122. The suture 128 is then secured between a distal terminus of the threaded plug 104 and the distal terminus of the suture anchor cannulation 118. The distal advancement of the threaded plug 104 further positions the threaded plug 104 fully within the anchor 102 and unengaged with the inserter 106. This position defines a second axial position, wherein the threaded plug 104 engages the anchor body 114 but not the outer shaft 108 of the inserter 106, and the distal terminus of the threaded plug 104 abuts the distal terminus of the anchor body cannulation 118. Accordingly, the inserter 106 (both the inner shaft 112 and outer shaft 108) is fully retracted from the anchor 102, leaving the anchor 102, the threaded plug 104, and the suture 128 secured to the bone hole.

FIG. 3 shows an alternative example of the suture anchor system of this disclosure. As shown in FIG. 3 , the geometry of the anchor 304, the plug 302 and the outer shaft 308 can be manipulated to the point where the plug 302 can sit within the outer shaft 308, yet still perform the same function.

Although the invention has been described with respect to various embodiments, it should be realized this invention is also capable of a wide variety of further and other embodiments within the spirit and scope of the appended claims. 

The invention claimed is:
 1. A suture anchor system, comprising: an inserter including a shaft with a cannulated distal end, the cannulated distal end including a threaded portion; and an anchor, comprising: an eyelet, extending transversely through a longitudinal axis of the anchor dimensioned to receive one or more sutures; a cannulation extending along the longitudinal axis of the anchor, the cannulation including a threaded portion; and a plug having a threaded external surface that threadingly couples directly to both the shaft threaded portion and anchor cannulation threaded portion, and thereby operatively couples the anchor to the inserter.
 2. The suture anchor system of claim 1, wherein the plug is also configured to advance axially along the anchor cannulation to threadingly disengage from the inserter and at least partially occlude the eyelet.
 3. The suture anchor system of claim 1, wherein the anchor cannulation also includes a non-threaded portion.
 4. The suture anchor system of claim 1, wherein the anchor and the shaft distal end are also telescopically mated with each other.
 5. The suture anchor system of claim 1, wherein the distal end of the shaft is coextensive with the anchor independent of a position of the plug.
 6. The suture anchor system of claim 1, wherein the anchor and anchor is comprised of a plastic, a bioabsorbable material or a metal.
 7. The suture anchor system of claim 1, wherein the plug has a distal non-threaded portion.
 8. The suture anchor system of claim 1, wherein the inserter further comprises an inner shaft, axially moveably within the inserter shaft and configured to advance the plug distally with respect to the anchor by rotating.
 9. A suture anchor system, comprising: an inserter including a shaft with an internally threaded cavity at an inserter distal end; and an anchor, comprising: an eyelet, extending transversely through a longitudinal axis of the anchor for receiving one or more sutures therethrough; a cannulation extending along the longitudinal axis of the anchor, the cannulation including a threaded portion; and a threaded plug configured to threadingly couple the anchor to the inserter internally threaded cavity and wherein the plug is also configured to advance axially along the anchor cannulation to both threadingly disengage the anchor from the inserter and at least partially secure the one or more sutures within the eyelet.
 10. The system of claim 9 wherein the inserter distal end is also configured to telescopically couple with the anchor.
 11. The system of claim 9 wherein threadingly coupling the plug directly to both the anchor and inserter provides a force transmission bridge between the anchor and inserter so as to provide linear stability to the system and thereby replacing an auxiliary coupling suture connecting the anchor and the inserter.
 12. The system of claim 9 wherein the plug is further configured to advance axially and at least partially extend across the eyelet.
 13. The suture anchor system of claim 9, wherein the inserter further comprises an inner shaft, axially moveably within the inserter shaft and configured to advance the plug distally with respect to the anchor by rotating.
 14. The suture anchor system of claim 9, wherein the inserted distal end is coextensive with the anchor, independent of a position of the plug.
 15. A suture anchor system, comprising: an inserter including a shaft with a cannulated distal end, the cannulated distal end including a threaded portion for selectively threadingly coupling directly with threads of an anchor plug; and an anchor, comprising: an eyelet, extending transversely through a longitudinal axis of the anchor dimensioned to receive one or more sutures; a cannulation extending along the longitudinal axis of the anchor, the cannulation including a threaded portion for threadingly coupling to the anchor plug threads.
 16. The suture anchor system of claim 15, wherein the anchor and the shaft distal end are telescopically engaged with each other.
 17. The suture anchor system of claim 15 wherein the distal end of the shaft is configured to coextensively mate with the anchor.
 18. The system of claim 15 wherein when the inserter is threadingly coupled to the plug, the plug provides a force transmission bridge between the anchor and inserter so as to gain linear stability.
 19. The system of claim 15 wherein the plug is further configured to advance axially, disengage with the threaded portion of the inserter and secure a length of suture with the anchor.
 20. The suture anchor system of claim 15, wherein the inserter further comprises an inner shaft, axially moveably within the inserter shaft and configured to advance the plug distally. 